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research article

High-fidelity thermomechanical simulation of laser powder bed fusion process: Impact of constitutive model choice

Markovic, P.
•
Scheel, P.
•
Wróbel, R.
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December 1, 2025
Additive Manufacturing Letters

Laser Powder Bed Fusion (LPBF) is a widely adopted metal additive manufacturing technology that enables the fabrication of intricate metal components, yet it faces challenges arising from intrinsic residual stress and distortion development. High-fidelity thermomechanical simulations offer essential insights for predicting and mitigating these effects. The reliability of such simulations depends on various factors, but critically on the material input data, primarily the constitutive model which should accurately represent the material's deformation behaviour under the complex loading conditions expected during LPBF. The present study integrates an advanced elastic-viscoplastic constitutive model into the LPBF thermomechanical simulation, capable of capturing the cyclic response of LPBF Hastelloy X across a broad range of temperatures and strain rates, and accounting for both isotropic and kinematic hardening. Simulation outcomes are validated against in-situ temperature and distortion measurements obtained during an LPBF experiment for Hastelloy X. Acknowledging the extensive effort required to develop such an advanced constitutive model, this study also calibrates three alternative models of simpler formulation to assess the impact of model selection on simulation outcomes and computational cost. The four investigated models span from rate-dependent elastic-viscoplastic to rate-independent elastic-plastic formulations, each with different capabilities for representing the alloy's cyclic hardening response. The results provide valuable insights into trade-offs between simulation accuracy, constitutive model development effort, and computational efficiency in LPBF thermomechanical simulations.

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Type
research article
DOI
10.1016/j.addlet.2025.100324
Scopus ID

2-s2.0-105016409146

Author(s)
Markovic, P.

Empa - Swiss Federal Laboratories for Materials Science and Technology

Scheel, P.

Empa - Swiss Federal Laboratories for Materials Science and Technology

Wróbel, R.

Empa - Swiss Federal Laboratories for Materials Science and Technology

Van Petegem, S.

Paul Scherrer Institut

Leinenbach, C.  

École Polytechnique Fédérale de Lausanne

Mazza, E.

Empa - Swiss Federal Laboratories for Materials Science and Technology

Hosseini, E.

Empa - Swiss Federal Laboratories for Materials Science and Technology

Date Issued

2025-12-01

Published in
Additive Manufacturing Letters
Volume

15

Article Number

100324

Subjects

Constitutive model

•

Distortion

•

Hastelloy X

•

High-fidelity thermomechanical simulation

•

Laser powder bed fusion

•

Residual stress

Editorial or Peer reviewed

REVIEWED

Written at

EPFL

EPFL units
LPMAT  
FunderFunding(s)Grant NumberGrant URL

ETH Zürich

SNSF

200551

Available on Infoscience
September 29, 2025
Use this identifier to reference this record
https://infoscience.epfl.ch/handle/20.500.14299/254415
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